Influence of elliptical vibration on material removal and surface quality in rotary ultrasonic elliptical machining of Cf/SiC composites

Achieving precise and cost-effective processing of ceramic matrix composites (CMCs) remains a critical yet unresolved issue in aerospace applications, attributed to their unique hardness, brittleness, and anisotropic properties. Among emerging solutions, rotary ultrasonic elliptical machining (RUEM) applied to C f /SiC composites in which transversal elliptical vibration is applied on diamond grinding tools seems to be a promising technique. Nevertheless, the material removal and machined surface quality is unexplored. This study investigates therefore the feasibility of RUEM of C f /SiC composites by evaluating the resulting cutting forces, surface quality, and tool wear. Experimental data reveal that, relative to conventional machining (CM) methods, RUEM reduces cutting forces by 2% to 28% and decreases chip size significantly. Regarding surface quality, RUEM optimizes the material removal mechanism by converting macro-brittle fractures into micro-brittle fractures, resulting in improved surface quality and lower three-dimensional surface roughness. Furthermore, RUEM effectively minimizes adhesive wear and prevents abrasive grain pullout, significantly prolonging tool life. These findings demonstrate that RUEM offers multiple machinability advantages for C f /SiC composites, hence, it is an excellent technique for high-performance machining of CMCs.